Engineered air EngA CU Series Installation, Operation And Maintenance Manual

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CANADIAN

HEAD OFFICE

AND FACTORY

1401 HASTINGS CRES. SE

CALGARY, ALBERTA

T2G 4C8

Ph: (403) 287-4774

Fx: 888-364-2727

SALES OFFICES ACROSS CANADA AND USA

Retain instructions with unit and maintain in a legible condition.

Please give model number and serial number when contacting

IOM-14

INSTALLATION, OPERATION

AND MAINTENANCE MANUAL

CU SERIES

CONDENSING UNITS

INDOOR AND OUTDOOR MODELS

UNIT MODEL NO. _________________

UNIT SERIAL NO. _________________

SERVICED BY: ___________________

TEL. NO: ________________________

HEAD OFFICE

AND FACTORY

32050 W. 83

DESOTO, KANSAS

Ph: (913) 583-3181

Fx: (913) 583-1406

factory for information and/or parts.

www.engineeredair.com

FOR

USA

STREET

66018

CANADIAN

EASTERN FACTORY

1175 TWINNEY DRIVE

NEWMARKET, ONTARIO

L3Y 5V7

Ph: (905) 898-1114

Fx: (905) 898-7244

Feb 06 R4

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Summary of Contents for Engineered air EngA CU Series

Page 1 INSTALLATION, OPERATION AND MAINTENANCE MANUAL CU SERIES CONDENSING UNITS INDOOR AND OUTDOOR MODELS UNIT MODEL NO. _________________ UNIT SERIAL NO. _________________ SERVICED BY: ___________________ TEL. NO: ________________________ CANADIAN CANADIAN HEAD OFFICE HEAD OFFICE EASTERN FACTORY AND FACTORY AND FACTORY 1401 HASTINGS CRES. SE 32050 W.
Page 2: Table Of Contents
CU MANUAL TABLE OF CONTENTS YOU HAVE RESPONSIBILITIES TOO ........................... 3 INTRODUCTION ................................3 SAFETY PRECAUTIONS ..............................3 WARRANTY ..................................4 PARTS ....................................4 RECEIVING ..................................5 TEMPORARY STORAGE ..............................5 INSTALLATION ................................... 5 CODES ....................................6 In Canada: ..................................6 In USA: ....................................
Page 3: You Have Responsibilities Too
INTRODUCTION Engineered Air units are high quality products designed and manufactured to provide many years of trouble-free operation. We recommend that this manual be read thoroughly to ensure proper installation, efficient operation and proper maintenance of this equipment.
Page 4: Warranty
Under no circumstances shall ENGINEERED AIR be liable to, nor be required to indemnify, Buyer or any third parties for any claims, losses, labour, expenses or damages (including special, indirect, incidental, or consequential damages) of...
Page 5: Receiving
Motor manufacturers have service centers that will repair or replace motors as required. Parts Other Than Motors: Contact the nearest Engineered Air sales office or factory. Be sure to include Model Number, Serial Number, date of installation and nature of failure along with the description of the parts required.
Page 6: Codes
CU MANUAL Note: Installation shall be in accordance with this manual and all other associated component and control Installation, Operation and Maintenance Manuals. CODES In Canada: The installation of this unit shall be in accordance with the latest edition of the Canadian Electrical Code, Part 1 –...
Page 7: Qualified Installer
CU MANUAL Note: The minimum clearance for proper air flow is 60” (1500 mm) to obstructions and 96” (2400 mm) to an adjacent condensing unit or air conditioning unit. QUALIFIED INSTALLER To complete the installation, an air-conditioning contractor experienced and qualified in system piping is required.
Page 8: Piping Recommendations
CU MANUAL 2. Condensing Unit At The Same Elevation As The Evaporator. Select suction and liquid lines from the appropriate tables. Horizontal suction lines should slope down in the direction of flow with a 1:200 slope. 3. Condensing Unit Located Below The Evaporator. This arrangement should only be considered when other options are not available.
Page 9 CU MANUAL Suction line accumulators and crankcase heaters are required on all systems with underground piping. Consult factory for guidance. IOM-14 9 of 46 Feb 06 R4...
Page 10 CU MANUAL PIPING CONNECTION SIZES Refrigerant piping must be selected to meet the conditions required for your specific installation. The tubing connection sizes on the condensing unit and/or evaporator may or may not be the correct size for your specific application. NOTE: DO NOT select tubing sizes based on the size of the connection stubs.
Page 11 CU MANUAL Condensate Line (Systems with Receivers Only) The condensate line connects the condenser to the liquid receiver. This is perhaps one of the most critical and misunderstood lines in a system. Condensate lines contain liquid and gas together, and are sized and installed to provide sewer flow to the receiver.
Page 12 CU MANUAL Hot Gas Solenoid Valves (Required When Equipped With A Hot Gas Bypass Valve) Whenever a system is equipped with hot gas bypass valve, a hot gas solenoid valve is required. The valve will open and close with the liquid line solenoid valve. The hot gas bypass solenoid valve must be installed at the condensing unit, close to the discharge line tee.
Page 13 CU MANUAL IOM-14 13 of 46 Feb 06 R4...
Page 14 FUSIBLE PLUG ORIFICE Underground piping will void compressor warranty unless specifically authorized by SUCTION ACCUMULATOR Engineered Air. Accumulators are STRONGLY RECOMMENDED on: 100% Outside air systems. VAV systems. Process cooling systems that experience rapid load changes. Condensing units may be ordered with suction accumulators installed at the factory (optional) or they may be field supplied and installed.
Page 15 CU MANUAL Liquid Receivers (Optional) NOTE: Liquid receivers MUST NOT be field installed unless the air-cooled condenser has been specifically designed for use with a receiver. If receivers are required the condenser coil must be ordered with a “receiver ready” condenser coil (optional) or a factory installed receiver (optional).
Page 16 50°F (10°C) ambient. Above 20°F (-7°C) Package This package will have condenser fan motors operating at extended pressures. An Engineered Air Intercooler is included, and is installed between the TX valve and the distributor to allow ‘just in time’...
Page 17: Pipe Selection Procedure
Record the actual distance the piping must be run to connect the components. Refer to Submittal Record for maximum allowed line length. If exceeded, please contact an Engineered Air office. Determine the number of fittings required. Include all fittings required for traps etc.
Page 18 CU MANUAL Suction line 1 5/8” Liquid line 5/8” Refrigeration Table 1 Equivalent Length. Approximate pressure loss of fittings ACR (OD) (equivalent feet of tubing) 90° Tubing 90° 90° 45° Return Ball Globe Angle Long Branch Straight Size Street Bend Valve Valve Valve...
Page 19 CU MANUAL Refrigeration Table 2 (R407c) Piping Guidelines for Normal Air Conditioning Duty. R-22 / 407C Equivalent Length Evaporator Maximum (Actual length plus fittings and valves) Capacity Riser Size Tons Line 30 feet 50 feet 100 feet 150 feet 3 tons Suction 3/4”...
Page 20 CU MANUAL Refrigeration Table 2 (R410a) Piping Guidelines for Normal Air Conditioning Duty. R410a Equivalent Length Evaporator Maximum (Actual length plus fittings and valves) Capacity Riser Size Tons Line 30 feet 50 feet 100 feet 150 feet 3 tons Suction 3/4”...
Page 21 CU MANUAL Refrigeration Table 2 (R134a) Piping Guidelines for Normal Air Conditioning Duty. R134a Equivalent Length Evaporator Maximum (Actual length plus fittings and valves) Capacity Riser Size Tons Line 30 feet 50 feet 100 feet 150 feet 3 tons Suction 7/8”...
Page 22 CU MANUAL 3. Selections are based on Equivalent length. Equivalent length is the actual length plus the additional losses in feet due to fittings. See Table 1 for pressure losses due to fittings. (If number of fittings is unknown an equivalent length estimate can be made by multiplying the actual piping run by a complexity factor of 1.5 to 2 times the actual length.
Page 23: Piping Materials And Procedures
CU MANUAL PIPING MATERIALS AND PROCEDURES A qualified refrigeration contractor experienced in refrigerant piping must complete the NOTE: installation. The installation must be completed using industry-accepted methods and materials. WARNING: The condensing unit is shipped with a holding charge of dry nitrogen. This pressure shall be released safely before opening system or connecting tubing.
Page 24 CU MANUAL WARNING: Test pressures must not exceed the maximum pressure ratings specified on the unit rating plate. WARNING: Oxygen must NEVER be used to pressurize a system. If leaks are located, remove pressure and repair leaks. Recheck as necessary. If brazing is necessary to repair leaks, a dry nitrogen purge through tubing while brazing is required to prevent the formation of copper oxides.
Page 25: Clearance For Condenser Air Flow
CU MANUAL Pressurize the system to a slight positive pressure, (one or two psig). Replace all Schraeder valve cores. Do not allow air into the system. Reinstall gauges, proceed to the start-up section for charging instructions. NEVER use system compressors to evacuate a system. Operating a compressor while the CAUTION: system is under a high vacuum may cause internal arcing of the windings and compressor failure.
Page 26: Lifting
CU MANUAL LIFTING Engineered Air units are constructed on a structural steel base frame. The unit base frame is equipped with lifting lugs specifically located to facilitate proper lifting of the unit. Spreader bars must be used to keep rigging away from the unit cabinetry. All lifting lugs must be used. If using a lift truck, ONLY lift using the perimeter structural frame.
Page 27: Shipping Materials
The gasket material provided for the split is open cell foam. Open cell foam is light and compresses easily. If the unit is mounted on a curb provided by Engineered Air there will also be gasket material for sealing the curb. The gasket material for curbs is closed cell foam. It is more dense than open cell foam and does not compress as easily.
Page 28: Electrical Installation
CU MANUAL All penetrations through the unit walls must be caulked and sealed to prevent air and/or water from entering the unit. ELECTRICAL INSTALLATION DO NOT install anything that will interfere with equipment access or the rating plate. The unit must be electrically grounded and all wiring must be installed in accordance with the National Electrical Code, ANSI/NFPA 70, and/or the Canadian Electric Code CSA 22-1 and to the approval of the authorities having jurisdiction.
Page 29: Before Start-Up
CU MANUAL The field wiring load depends on the actual load on a particular control circuit the field wiring is connected to. Refer to the internal wiring diagram of the unit. The table above is based on a maximum 10% voltage drop on a 24V control circuit. Wire size was calculated using the following formula: CM = (25 x I x L ) / V Where CM is circular mils of conductor for a constant load of I amps, wire length L in feet from the...
Page 30 CU MANUAL Check drive alignment and belt tension. Refer to Maintenance, page 36. Ensure that refrigerant lines and control capillary lines do not rub against cabinet or other lines. Inspect all electrical wiring, both field and factory installed, for loose connections. Ensure fire alarm contact is installed, or jumpered if not required.
Page 31 CU MANUAL phase to phase voltage imbalance should be less than 2%. A 2% voltage imbalance can cause up to a 10% current imbalance that will overheat motor windings. To calculate voltage imbalance (NEMA method) refer to the following example: Phase to phase voltage readings: 235V 236V 230V The average Voltage between legs is 233.7V (235+236+230)/3...
Page 32 CU MANUAL Check system charge: When thermostatic expansion valves (TX valves) are provided, the charge can be checked with the liquid line sight glass. Under normal operating conditions the sight glass is clear of bubbles. Refer to Charging Instructions. NOTE: It is possible for conditions other than low refrigerant charge to cause the sight glass to bubble.
Page 33: Initial Start-Up
CU MANUAL INITIAL START-UP WARNING: To prevent possible injury to personal or equipment damage, the start-up shall be performed by a Qualified Personal. Check all packing material has been removed. Check that shipping blocks and fasteners have been removed. Check condenser fans to ensure they spin freely. Check all electrical connections for tightness.
Page 34: Operation
CU MANUAL With the saturated discharge temperature approximately equal to 130°F (55°C), [300 psig (R-22) 325 psig (R-407C)] This step may require blocking condenser airflow to increase head pressure. Charge system slowly until the sight glass is clear. DO NOT OVERCHARGE. Check evaporator superheat.
Page 35: Shutdown Procedure
CU MANUAL Caution: When recovering refrigerant from a system equipped with a water cooled condenser, the water valve must be manually opened so water flows continuously through the condenser while the refrigerant is being recovered. Failure to do so can cause the condenser to freeze, which will permanently damage the condenser.
Page 36: Maintenance
Property damage or personal injury claims may result from mold or biological growth arising from improper installation, inadequate maintenance, or failure to inspect. Engineered Air has no responsibility for and makes no express or implied warranties regarding mold or bacterial growth or any other indoor air quality issues.
Page 37 CU MANUAL NOTE: If belts are too tight or improperly aligned, the life expectancy of the motor(s), fan bearings and belt(s) are reduced. Alignment: Pulleys must be aligned to within 1/16” per foot (1mm per 760mm) of span. FOR FANS EQUIPPED WITH SPIDER BRACKETS: A properly adjusted V-belt rides the inside of the pulley faces.
Page 38: Bearing Setscrew Torques
CU MANUAL BEARING SETSCREW TORQUES TABLE I Shaft KOYO KOYO DODGE diameter UC SERIES UK SERIES Type SC 203-215 SERIES (set screw) (adapter sleeve locknut) 3/4" Install the washer and 66 - 80 in-lb (7.5 - 9 35 in-lb (3.9 Nm) 35 in-lb (4.0 Nm) (19mm) lock nut;...
Page 39 CU MANUAL LUBRICATION OF FAN BEARINGS Some fans have permanently lubricated sealed ball bearings which should not require lubrication. These bearings are factory packed 30 to 50% full. Bearings that require lubrication should be greased while the bearing is rotating slowly, with the following quantities of a lithium base lubricant. DO NOT OVERGREASE.
Page 40 CU MANUAL Suggested Re-lubrication Schedule (Months)* for Dodge Spherical Roller Bearing - Solid Pillow Block Speed (RPM) 1000 1500 2000 2500 3000 3500 4000 4500 Shaft DIA. 3/16” 7/16” – 1 11/16” 3/16” – 2 7/16” 7/16” – 3 15/16” 15/16”...
Page 41: Filters
CU MANUAL Shell Alvania No. 2 Mobil Mobilith AW2 Mobilith SHC100 Texaco Premium RB2 American Rykon Premium 2 Lubricate bearings prior to extended shutdown or storage and rotate shaft monthly to aid corrosion protection. Static Oil Lubrication Use only highest quality mineral oil with a minimum viscosity of 100 SSU at the oil’s operating temperature.
Page 42: Controls
Shake off excess water and re-install. These filters do not require an oil adhesive. Pleated Throwaway and/or Replaceable Media (Cartridge, Bag): Replacement filters can be obtained from any Engineered Air representative. In some applications the used filters/media may contain chemical or biological hazards. All local, regional and national regulations for safety and disposal should always be followed.
Page 43 CU MANUAL  On units with sight glasses, check for bubbles. There should be no foaming under steady state operation.  Water Cooled Condensers - With time, condensers can foul with mineral deposits from the water, resulting in a reduced heat transfer capacity and increased refrigerant head pressure. Should this condition occur, the condenser coil should be chemically cleaned or replaced.
Page 44 CU MANUAL IOM-14 44 of 46 Feb 06 R4...
Page 45: Troubleshooting Chart
CU MANUAL TROUBLESHOOTING CHART Symptoms Problem Cure Compressors not No power Restore power to unit. running Blown Fuse or breaker Replace fuse or reset breaker Low voltage Find and correct reason for low voltage Faulty control system Check and repair as required Open safety contacts Check safety controls and identify and correct problems...
Page 46 CU MANUAL TX valve not opening Check for high superheat and correct problem as required. High Suction System load higher than Determine reason for high load and correct as pressure design necessary. Too much air flow Check airflow, balance system air. Check blower speed.